Method of making a composite panel and article made thereby

• US 20030165664A1
• Filed: 03/01/2002
• Published: 09/04/2003
• Est. Priority Date: 03/01/2002
• Status: Abandoned Application

• Current Assignee: Oakwood Custom Coating, Inc.
• Original Assignee: Oakwood Custom Coating, Inc.
• Inventors: Carroll, Phillip Patrick III, Brooks, Ryan Johnson
• Application Number:
  US10/087,050
• Publication Number:
  US 20030165664A1
• Time in Patent Office: Days
• US Class Current: 428/138
• CPC Class Codes: B29C 2043/3644 Vacuum bags; Details thereof, e.g. fixing or clamping
• CPC Class Codes: B29C 43/02 of articles of definite length, i.e. discrete articles B29C35/0227 takes precedence
• CPC Class Codes: B29C 43/10 Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
• CPC Class Codes: B29C 65/00 Joining or sealing of preformed parts , e.g. welding of plastics materials; Apparatus therefor general aspects of processes or apparatus for joining preformed parts B29C66/00; using porous material formed by internal pressure generated therein for joining preformed parts B29C44/1228, B29C44/326
• CPC Class Codes: B29C 65/02 by heating, with or without pressure
• CPC Class Codes: B29C 65/08 using ultrasonic vibrations non-plastics element to plastics elements B29C65/645
• CPC Class Codes: B29C 65/606 the rivets being integral with one of the parts to be joined, i.e. staking
• CPC Class Codes: B29C 66/1122 Single lap to lap joints, i.e. overlap joints B29C66/45, B29C66/472, B29C66/52272 take precedence
• CPC Class Codes: B29C 66/474 said single elements being substantially non-flat
• CPC Class Codes: B29C 66/71 characterised by the composition of the plastics material of the parts to be joined welding bar compositions B29C65/125
• CPC Class Codes: B29C 66/72329 Wood
• CPC Class Codes: B29C 66/8322 Joining or pressing tools reciprocating along one axis
• CPC Class Codes: B29C 66/843 Machines for making separate joints at the same time in different planes; Machines for making separate joints at the same time mounted in parallel or in series
• CPC Class Codes: B29K 2023/00 Use of polyalkenes or derivatives thereof as moulding material
• CPC Class Codes: B29K 2055/02 ABS polymers, i.e. acrylonitrile-butadiene-styrene polymers
• CPC Class Codes: B29K 2069/00 Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
• CPC Class Codes: B29L 2031/3014 Door linings
• CPC Class Codes: B29L 2031/3041 Trim panels
• CPC Class Codes: B32B 3/02 characterised by features of form at particular places, e.g. in edge regions non-uniform thickness B32B3/263
• CPC Class Codes: B60R 2013/0293 Connection or positioning of adjacent panels
• CPC Class Codes: Y10T 428/24331 : including nonapertured component
• CPC Class Codes: Y10T 428/24339 : Keyed
• CPC Class Codes: Y10T 428/24438 : Artificial wood or leather grain surface

Abstract

A trim panel (1) and a method of making a trim panel (1) comprising providing a formable sheet (12) having at least one layer, locating the sheet (12) adjacent to a forming surface (80), conforming the sheet (12) to the forming surface (80) so that the sheet (12) has a characterizing topography (15) and removing the sheet (12) from the forming surface (80). A substrate (40) is provided having a rear surface (45) and an opening (55) therethrough. Lastly, the sheet (12) is attached to the rear surface (45) of the substrate (40) so that the characterizing topography (15) extends through the opening (55). Alternatively, the sheet (12) may comprise at least one tab (17) and the substrate (40) may comprise at least one tab opening (57) wherein the tab (17) is inserted into the tab opening (57) to snap-fit the pieces together.

Claims

1. A method of making a composite panel comprising:

providing a formable sheet having at least one layer;

locating the formable sheet adjacent to a forming surface;

making a formed sheet by conforming the formable sheet to the forming surface so that a characterizing topography projects from the formable sheet;

removing the formed sheet from the forming surface;

providing a substrate having a front surface, a rear surface, and an opening therethrough; and

attaching the formed sheet to the rear surface of the substrate so that the characterizing topography appears through the opening.

2. The method of claim 1 wherein the substrate further comprises a plurality of bosses extending from the rear surface.

3. The method of claim 2 further comprising the step of:

forming a plurality of openings through the formed sheet before the formed sheet is attached to the substrate.

4. The method of claim 3 wherein the step of attaching the formed sheet to the substrate comprises placing the formed sheet on the substrate so that at least one of the plurality of bosses extends through one of the plurality of openings.

5. The method of claim 4 wherein the step of attaching the formed sheet to the substrate further comprises the step of:

heat staking the bosses extending through the holes in the formed sheet.

6. The method of claim 4 wherein the step of attaching the formed sheet to the substrate further comprises the step of:

upsetting the bosses extending through the openings in the formed sheet.

7. The method of claim 1 wherein the step of attaching the formed sheet to the substrate further comprises applying adhesive to a portion of at least one of the formed sheet and substrate.

8. The method of claim 1 wherein the step of providing a formable sheet comprises the step of providing a sheet with at least one simulated wood grain layer.

9. The method of claim 1 wherein the step of providing a formable sheet comprises the step of providing a sheet with at least one decorative layer.

10. The method of claim 1 further comprising the step of:

trimming the formed sheet before attaching the formed sheet to the substrate.

11. A composite panel comprising:

a substrate having a front and a rear surface, an opening therethrough;

an insert panel having a characterizing topography extending therefrom;

wherein the insert panel is located on the rear surface of the substrate so that the characterizing topography appears through the opening; and

means to secure the insert panel to the substrate.

12. The composite panel of claim 11 wherein the substrate further comprises a plurality of bosses extending from the back surface, the insert panel further comprises a plurality of openings on the flat plane corresponding to the bosses, and wherein the insert panel is placed on the substrate so that at least one of the plurality of bosses extends through at least one of the plurality of openings.

13. The composite panel of claim 12 wherein the means for securing the insert panel to the substrate comprises a mechanical lock formed in the bosses extending through the openings.

14. The composite panel of claim 13 wherein the mechanical lock is formed by means for heat staking the bosses that extend through the openings.

15. The composite panel of claim 13 wherein the mechanical lock is formed by means for upsetting the bosses that extend through the openings.

16. The composite panel of claim 11 wherein means for securing the insert panel to the substrate comprise adhesive applied to a portion of at least one of the insert panel or substrate.

17. The composite panel of claim 11 wherein the insert panel comprises a plurality of layers.

18. The composite panel of claim 17 wherein one or more of the layers has a wood grain finish.

19. A method of making a composite panel comprising:

providing a formable sheet having at least one layer;

locating the formable sheet adjacent a forming surface;

making a formed sheet by conforming the formable sheet to the forming surface so that a characterizing form projects from the formable sheet and by forming a tab extending from the formed sheet;

removing the formed sheet from the forming surfaces;

providing a substrate having a front surface, a rear surface, and a tab opening therethrough; and

attaching the formed sheet to the substrate so that at least one tab extends through the tab opening to secure the formed panel to the substrate.

20. A composite panel comprising:

a substrate having a front and a rear surface;

at least one tab opening extending therethrough;

an insert panel having a characterizing topography and at least one tab extending therefrom;

wherein the insert panel is placed on the front surface of the substrate and the tab extends through the tab opening to secure the insert panel to the substrate.